Rust

[NickTheEnforcer]

nothing to be concerned about, now my 2016 Escape body panels started rusting from the inside out and at a lot of the body seams after only three years. FoMoCo 'claims there is a 5yr 'perforation' warranty for this BUT we got denied at every turn..yet another reason why I refuse to keep vehicles long-term anymore OR dump a lot of wasted money in doo-dads and aftermarket extras.
Phil could probably attest to this but back in the day Jeep used to galvi-dip the Grand Cherokee bodies in a 6-way process. those model years now long gone were the most rust free jeeps ever made and I owned one for 6 years and not one spot of inside-to out rust on it when I sold it.

Steel has a high iron ore content and from the moment its made oxidation wants to return it to this state.

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[P. A. Schilke]

nothing to be concerned about, now my 2016 Escape body panels started rusting from the inside out and at a lot of the body seams after only three years. FoMoCo 'claims there is a 5yr 'perforation' warranty for this BUT we got denied at every turn..yet another reason why I refuse to keep vehicles long-term anymore OR dump a lot of wasted money in doo-dads and aftermarket extras.
Phil could probably attest to this but back in the day Jeep used to galvi-dip the Grand Cherokee bodies in a 6-way process. those model years now long gone were the most rust free jeeps ever made and I owned one for 6 years and not one spot of inside-to out rust on it when I sold it.

Steel has a high iron ore content and from the moment its made oxidation wants to return it to this state.

Hi Anthony,

I think the change from a galvi-dip came when they invented single side galvanized sheet metal...

Best,
Phil Schilke
Ranger Vehicle Engineering
Ford Motor Co. Retired

 

[CO2Ranger]

Hi C02,

Each vehicle program has requirements for Salt corrosion performance as well as individual components. The whole vehicles are amazing, usually white, and after the full vehicle test they are incredibly corroded. They are usually driven across the pot hole course among other tests to see if the corrosion results in problems. I searched for pictures but my search skill set lacks being able to find pictures of these corrosion vehicles. Simply amazing what they look like. You have superficial corrosion of no harm in my opinion.

Best,
Phil Schilke
Ranger Vehicle Engineering
Ford Motor Co. Retired

Hey Phil,

I think if I saw one of those test trucks I might have an anxiety attack. ?

I figured the rust was superficial. I think the frustration is what rust on a vehicle typically conjures in people's minds (old, abused, falling apart). There's a certain emotional response when you see that on a brand new 40k+ vehicle. It just doesn't "feel" right.

I'm not worried, but I just don't like to see it. Greatly appreciate your stories as always! Thanks for sharing!

 

[TechnicallyReal]

A quick fix could be a quick touchup with Rustoleum flat black paint.

I'm planning to spray rust-converter on the areas of my truck that are like this. I haven't used it before, but from what I've read it chemically converts mild surface rust into something else that's black and won't rust any further. Should be a more permanent solution than paint I hope.

 

[JaysOnTheEDGE]

I looked at a bunch of '21 models sitting on the lot while getting an oil change and they all looked like the OPs photo.

 

[rang19ca]

That is a little bit of surface rust, nothing to worry about. I remember many new trucks, 30-35 years ago that had rusty rear axle housings, from the factory.

 

[2.7EcoBoost]

Will fluid film keep this minimized? I've got a spray can and gallon of the stuff but thought about having it down professionally since they can get it up on lift

I think fluid film is much better for use on inside panels where it doesn't get the road spray. I use it inside my doors and inside my frame and bed sides. CRC makes a good product that is more resistant to washing off from road spray and is better for the outside of the frame. It is only available in cans, but I'm sure there's other stuff out there too. I looked under my 2019 and the only place I see surface rust is on the inner axle shafts and a very minimal amount on my rear axle. I live in a high rust state that uses harsh anti icing garbage too.

the OP isn't the only new ford owner noticing rust under their new truck, in this case a F150.

See the Rust Under Our Brand-New 2021 Ford F-150 | News | Cars.com

I want to know who saved the money here. Ford or the axle manufacturer? I'm pretty sure it wasn't the person who just financed $40k,$50k,$60k..... Ford says "it's normal for "some" (always love that) to show rust, however it won't affect performance or longevity. Maybe true, but I saw a guy on the F-150 forum I still visit now and then, whose axle looked like it was off a 77' Chevy and was staining his epoxy garage floor where it was dripping after pulling the truck in after driving in the rain. That's BS for what people are paying for this stuff. My 2019 Ranger has 26,000 and is almost 2 years old and barely has any rust on the axle. I live in a high rust state that uses harsh anti icing garbage too.

 

[DukeCanBuildit]

I think a lot of us owners in northern areas, where salt and brine are heavily used, are snickering a bit at the level of shock and surprise from some of the posters on these threads. Especially from those wondering how their CA and FL trucks could possibly have rust.

Take a couple of deep breaths, it’s just a bit of surface rust that isn’t affecting the strength or integrity of the affected parts to a degree that is a concern.

From the second your truck left the assembly plant, it had plenty of exposure to the environment and corrosive elements before you took delivery - - - the assembly plant parking lot, the rail cars, vehicle haulers, test drives, the dealer lot, etc., etc. So, unless your truck was blister-packed after assembly and shipped in a covered trailer, it could easily have some surface rust on the underside.

Even if it showed up in pristine condition, every time you drive your truck, on pavement, dirt, or gravel, you subject it to a sandblasting that slowly strips areas of the painted parts on the underside of your truck. If your tire throws the odd rock or two, that can result in much deeper scratches in protective coatings.

Rust happens.

 

[kirby]

Sad news about the aluminum control arms. I'm surprised they're rusting so much something for me to keep aware off.

I did use POR and other stuff from amazon to reverse it on other cars, but personally I would just protect the nut/bolt vs the whole part. IT can be sandblasted down the road, but just... it's meant to be used.

Don't coat it though, that'd just trap water and make things much worse.

 

[2.7EcoBoost]

with all the rust complaints about parts that no one sees unless you run them over on the sidewalk, and wont fail because the surface is the only thing oxidising, just keep voicing your concerns to Ford. if you become the vocal majority, (or annoying minority) and Ford feels its a justifiable complaint that needs to be corrected then maybe the parts suppliers will be forced to paint them better for cosmetic reasons. Maybe a nice metallic flake black would suit the situation?
These are robust parts that wont fail for surface oxidation, and every one of us is aware of the aftermarket products, both cheap and expensive to solve the issue.
I look under mine and see the same, but i also look under the yellow pages for crown rustproofing and the local shops that do oil spray and know that if it bugs me enough, i can drop some cash in their pocket and solve the issue too.
Ford would likely raise the price of the truck further, or delete more options to cover the cost and maintain their profit margin.

so in closing....you think its a problem....exercise your options. sadly the forums powers cant make rust magically disappear on its own.

Good point. Why hold a company accountable and expect a quality product for $40k? We can spend a day and $500 paying someone to complete the factory build with rust proofing. LOL.

 

[Deathrider]

I swear by Amsoil Heavy duty metal protector, it is oil based and turns into a wax, just spray all over underneath and wheel wells

 

[2.7EcoBoost]

I think a lot of us owners in northern areas, where salt and brine are heavily used, are snickering a bit at the level of shock and surprise from some of the posters on these threads.

I'm not snickering. I have not touched my rear axle and it has barely a sign of surface rust afer 26k miles and 20 months. People should not have rusted welds at 600 miles living in the "sunshine" state. Sorry. That's poor manufacturing and bean counters at work. That's what ruins company's. If I see a bird that looks like a duck, walks like a duck and quacks like a duck.....I call it a duck. That's just me. I am also the guy who paints under his rocker panels, fluid films inside his frame etc. But, at some point, consumers need to stop being blinded by brand loyalty or outright ignorance/stupidity and demand better.

 

[Langwilliams]

ya still bought it.
ya still signed on the bottom line and accepted it as presented.
that means you were ok with paying 40K for what you got.

how many guys go and ceramic coat their paint?
how many guys tint their windows to protect from UV
how many guys add mud flaps, bug guards and such to protect from rock chips

is this something you think the factory should do for you too?

I'm a die hard Ford guy an I'm disappointed by this surface rust. I don't think it's too much to ask to have the axle housings an other parts not rust for the 5 years I'm making payments. I can see Ford losing brand loyalty over stuff like this. You may laugh at it...another guy might go buy a Toyota over it next time he gets a new truck.

 

[Langwilliams]

you'll be just as disappointed there too

https://www.tacomaworld.com/threads/undercarriage-rust.625510/

I would never buy a Toyota myself....just sayin people change brands for different reasons. My ex's dad bought GM's every time since about 1970....then one day (around 2005ish) he buys a new Toyota. something pissed him off an he never went back. I've bought around 15 new cars an only 4 were not fords (ex wife's choice) an had good luck with them....I had a 2002 taurus that was crap but it was leased so getting rid of it was painless.

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